Audi Workshop Service and Repair Manuals

Removing and installing clutch slave cylinder Special tools and workshop equipment required

t  Hose clamps, up to Ø 25 mm -3094- t  Lithium grease -G 052 150 A2- t  Copper grease (commercially available) Removing   Note t  If you suspect a defective clutch master cylinder, perform function test prior to renewing → Chapter „Notes on removing and installing clutch master cylinder and slave cylinder“. t  Do not allow brake fluid to come into contact with the gearbox. If necessary, clean the gearbox housing.   Caution Make sure you do not press the clutch pedal if the clutch slave cylinder is removed from the gearbox with the pipe/hose assembly still attached. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed.

–  If fitted, loosen quick-release fasteners -2- and -3- and remove rear noise insulation -B-.

Vehicles with 6-cylinder engine: –  Disconnect exhaust system at clamp (left-side) -left arrow-.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged. –  Remove front exhaust pipe (left-side) with catalytic converter → Rep. gr.26.

–  Remove heat shield -arrows- for drive shaft (left-side). Continued for all vehicles: –  If fitted, unbolt drive shaft (left-side) -1- from flange shaft and move to front, taking care not to damage surface protection.

–  Unscrew nut -arrow- and detach gearbox selector lever from selector shaft.

–  Remove bolt -arrow- and take out clutch slave cylinder from the rear.   Note Do not depress clutch pedal after removing slave cylinder.

–  Using hose clamp -3094-, clamp off pipe/hose assembly. –  To remove pipe/hose assembly, use a screwdriver to lever out clip -A- as far as the stop. Only then can the pipe/hose assembly be pulled out. Installing Installation is carried out in reverse sequence; note the following:   Note t  Always renew securing bolt. t  When installing, press in slave cylinder so that securing bolt can be fitted easily.

–  Before inserting clutch slave cylinder in gearbox housing, lubricate area -a- of sleeve with lithium grease -G 052 150 A2-. –  Using copper grease (commercially available), lightly lubricate surface where plunger and clutch release lever make contact.

–  To connect pipe to clutch slave cylinder, press in retaining clip -A- as far as it will go. –  Push pipe -B- into clutch slave cylinder until it engages audibly. –  Pull pipe/hose assembly to check that it is securely seated.

–  Attach bracket for hose/pipe assembly -3- to clutch slave cylinder -4-.

–  Guide slave cylinder -1- into mounting hole in gearbox housing, keeping it as far as possible in line with the operating direction of the plunger -arrow A-. –  At the same time insert in recess -arrow B- on clutch release lever -3-. –  Secure slave cylinder -1- with new bolt -2-. Tightening torque → Item   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the clutch release lever -3-.   Caution t  After installing the slave cylinder carefully press the clutch pedal. t  If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. t  The plunger of the slave cylinder is likely to have been guided past the clutch release lever. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. t  For comparison: normal pedal force is approx. 115 N. –  If the pipe-hose assembly was disconnected at the slave cylinder, the clutch system has to be bled after installing slave cylinder → Chapter.

–  Install gearbox selector lever and tighten nut -arrow-. Tightening torque → Item –  If previously detached, bolt drive shaft (left-side) to flange shaft → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40 Vehicles with 6-cylinder engine: –  Screw heat shield for drive shaft (left-side) onto gearbox. –  Install exhaust system and perform stress-free alignment → Rep. gr.26. Tightening torques

Component	Nm
Heat shield for drive shaft to gearbox	23